High-voltage testing and insulation measurement serve no other purpose than personal protection. Mandatory by law in the DVGU and VDE 100, no toaster, fan or computer power supply can avoid this test, in which - depending on the device and component - voltages of up to 2.5 kilovolts are applied for a good second. However, this high-voltage test is very stressful for components and devices, especially if the applied potential of the measuring devices overshoots, i.e. if the test voltage briefly rises above the set potential and only then levels out again to the desired level. Although this uncontrolled overvoltage on the device under test only lasts a fraction of a second, it can still contribute to premature wear and tear and to failures within the warranty period, which manufacturers want to avoid at all costs.

Voltage overshoot extremely reduced

Developer and engineer Dieter Schwarz, from BDG Automationstechnik in Künzelsau-Amrichshausen in Baden-Württemberg, was able to reduce the so-called overshoot to a minimum using sophisticated circuit technology. The latest result of his research is a series of DC high-voltage measuring devices of the ElMeS type: "There are a lot of details in the two device versions. Mainly in the measurement technology, control technology and power electronics. Coupled with intelligent control software, we were able to achieve these goals." The rest is a trade secret. ElMeS is suitable for both the completely manual test bench and for full automation, adds Schwarz.

Two years development time

Among other things, the integrated web interface makes commissioning, ongoing operation and servicing of the test systems much easier for the user. This means that the customer benefits from all the requirements for Industry 4.0, such as the connection to Ethernet and the http API, as well as numerous programming examples and libraries when it comes to operation. Digital interfaces for user I/0, such as lamps and buttons, as well as the PLC connection are included.

Thanks to the recorded insulation measurement data, the QA department is able to take countermeasures in production at an early stage if it detects creeping changes in the test object, for example, so that no series failures of the products or components occur. Based on the measurement results, the user can produce his products in such a way that he stays within the calculated budget on the one hand and optimizes quality on the other. BDG offers two device versions for HV and insulation measurement: a compact built-in device that can be integrated directly on the test bench or in the fully automated system. The desktop device with a width of 19 inches is suitable for use in the laboratory, where test engineers can test with the same high-voltage testing technology as in fully automated systems.